Key cutting machine

ABSTRACT

A key cutting machine includes a housing, carriage, key clamp, and motor to drive the carriage. The key cutting machine may include a vacuum removably attached to the housing. The key cutting machine may be selected between manual, automatic, and semi-automatic user modes. Additional improvements or features of a key cutting machine are also described.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.14/310,729, now U.S. Pat. No. 9,550,263 to Ryai et al. filed on Jun. 20,2014, and titled KEY CUTTING MACHINE, which is a continuation of U.S.patent application Ser. No. 13/647,006, now U.S. Pat. No. 8,784,020 toRyai et al. filed on Oct. 8, 2012, and titled KEY CUTTING MACHINE, whichis a continuation of U.S. patent application Ser. No. 12/383,825, nowU.S. Pat. No. 8,292,556, to Ryai et al. filed on Mar. 27, 2009, andtitled KEY CUTTING MACHINE, which is a continuation of U.S. patentapplication Ser. No. 11/728,174, now U.S. Pat. No. 7,527,458, to Ryai etal. filed on Mar. 23, 2007, and titled KEY CUTTING MACHINE, which is acontinuation of U.S. patent application Ser. No. 10/970,844, now U.S.Pat. No. 7,214,011, to Ryai et al. filed on Oct. 20, 2004 and titled KEYCUTTING MACHINE, which claims priority from U.S. Provisional PatentApplication No. 60/512,636 to Ryai et al. filed on Oct. 20, 2003, andtitled KEY CUTTING MACHINE, all of which are hereby incorporated intheir entirety by reference

BACKGROUND

The present invention relates to key cutting machines that duplicate andcut the key pattern from a master key on to a key blank and, moreparticularly, to key cutting machines having features for improvedperformance and ease of operation.

Key cutting machines typically comprise a pair of vise grips or clampsmounted on a carriage. A master key having a keyway groove or grooves ifnecessary and a key pattern already cut therein is placed in one of thevise grips or clamps on the carriage and a key blank awaiting to be cuthaving an identical keyway groove or grooves as necessary is placed inthe adjacent vise grip or clamp on the carriage. The key pattern of themaster key faces a stylus or tracer bar on the key cutting machine andthe key blank faces a cutting wheel. The carriage is pivotally andlinearly movable along a longitudinal supporting shaft and presses thekey pattern of the master key against the tracer bar and the key blankagainst the cutting wheel. The carriage is then manually shiftedlongitudinally along supporting shaft thereby causing the key pattern onthe master key to travel on the tracer bar and impart correspondingpivotal movement to the carriage so that the cutting wheel cuts theidentical key pattern into the corresponding key blank. The key blankcut with the master key pattern is then removed from the vise or gripand buffed on a buffing wheel to remove any burrs.

While the above-identified description is directed to manual key cuttingmachines (machines in which the motion of the carriage results directlyfrom user manipulation), there are also similar automatic key cuttingmachines. Such automatic key cutting machines can have a similarstructure, but the carriage moves during the key cutting operation asdriven by the motor of the key cutting machine.

Further, regardless of the particular operational characteristics of akey cutting machine, metal shavings result from the cutting wheelcutting a key pattern into a key blank. These metal shavings canaccumulate if the key cutting machine is not cleaned on a regular basisand most advantageously after each key cutting operation. These metalshavings can fall into the housing of the key cutting machine anddisrupt the operation of the machine or cause injury to the operator asthey are very sharp and can cut an operator attempting to operate thekey cutting machine.

It is an object of the present invention to provide a key cuttingmachine that can be operated in three different modes; automatic,semi-automatic, and manual.

It is a further object of the present invention to provide a key cuttingmachine that is adaptable to utilize a vacuum system for removing metalshavings from the cutter area.

Yet another object of the present invention is to provide a key cuttingmachine having all motors and working parts mounted to the underside ofthe housing away from any metal shavings and dirt which gather below.

Yet another object of the present invention is to provide a computerinterface so that the key cutting machine may be operated according toinstructions from a Key I.D. system (as described in U.S. patentapplication Ser. No. 10/633,933, filed on Aug. 4, 2003, hereinincorporated by reference herein) or automatic feeder system.

DESCRIPTION OF THE DRAWINGS

Objects and advantages together with the operation of the invention maybe better understood by reference to the following detailed descriptiontaken in connection with the following illustrations, wherein:

FIG. 1 is a perspective view of the key cutting machine of the presentinvention.

FIG. 2 is an exploded view of the key cutting machine of FIG. 1.

FIG. 3 is a view of the carriage.

FIG. 4 is a side view of FIG. 3.

FIG. 5 is a left side view of the key cutting machine of FIG. 1.

FIG. 6 is a partial top view of the key cutting machine in thecarriage-down position.

FIG. 7 is a left side cross-sectional view of the key cutting machine inan engaged carriage-up position.

FIG. 8 is a front view of the key cutting machine of FIG. 7.

FIG. 9 is a fragmented cross-sectional view of the carriage in anengaged carriage-up cutting position.

FIG. 10 is a view of the carriage of FIG. 9 in its engaged carriage-upposition flexed away from the cutting position.

FIG. 11 is a cross-sectional view of the carriage locked in acarriage-down position.

FIG. 12 is a side view of a key blank.

FIG. 13 is a side view of a master key.

DETAILED DESCRIPTION OF THE INVENTION

The key cutting machine of the present invention, generally designatedas 10, is shown in the accompanying drawings. The key cutting machine 10as described herein has numerous features or improvements, each of whichare believed to be independently novel. Therefore, while the preferredembodiment of the present invention is described as utilizing each ofthese novel features or improvements in the aggregate, the appendedclaims should only be limited by the structure described therein andinterpreted independently of all other features or improvementsdescribed herein. The present description in conjunction with theaccompanying drawings should clearly enable one skilled in the art toreproduce the components and function of the key cutting machine. Thefollowing description will describe in detail the present invention withreference to the several drawings.

With reference to FIGS. 12 and 13, a brief introduction to key blanksand master keys is as follows. A key blank generally 100 comprises ahead 102, a shoulder 104, and a blade 106. Key blanks can also beprovided with keyway grooves 108 which are long, narrow, milled-outareas along the sides of the blade 106 that allow the blade 106 tobypass the wards in the keyway. Such keyway grooves 108 may already becut into a key blank so as to make the key cutting operation moresimplified. Therefore, when duplicating a master key, a key blank 100must be identified as either identical to or similar to the master key.The master key 110 is cut from a key blank 100 and like references aredescribed with like numerals. The master key 110 generally comprises ahead 102, a shoulder 104, a blade 106, and a keyway groove 108. However,the master key 110 has a key pattern 112 already cut into the blade 106.The particular key pattern 112 corresponds to the pin and tumbler designof a lock.

With reference to FIGS. 1 and 2, a brief description of the structure ofthe key cutting machine 10 of the present invention is as follows. Anexploded view showing the parts and assembly of the key cutting machine10 is shown in FIG. 2. The assembled key cutting machine is shown inFIG. 1. The key cutting machine 10 includes a pair of vise grips orclamps 12 having top jaws 14 and bottom jaws 16 which are mounted on acarriage 18. A master key 110 having a key pattern 112 already cuttherein is placed within the left-most clamp 12 on the carriage 18 and akey blank 100 awaiting to be cut having an identical keyway groove 108as the master key 112 is placed in the adjacent clamp 12 on the carriage18. The gauge fork 26 is used to align the master key 110 and the keyblank 100 in the correct and exact orientation within the clamps 12. Thecarriage 18 is mounted on a carriage rod 20 so that the carriage 18 ismoveable longitudinally along the carriage rod 20 and is also moveableradially so that the carriage 18 can be moveable between a carriage downposition (FIG. 11) and a carriage up position (FIG. 9). A switch 21automatically engages the motor when the carriage 18 is moved toward acarriage up position.

As best shown in FIG. 6, the key cutting machine 10 includes a stylus ortracer 22 that faces the key pattern 112 of the mounted master key 110.The cutting wheel 24 faces the mounted key blank 100. Therefore, as thecarriage 18 is pivotally and linearly movable along the longitudinalcarriage rod 20 and the master key 110 is pressed against the tracer 22,the key blank 100 is likewise pressed against the cutting wheel 24 tothe same depth as permitted by the tracer 22 against the master key 110and the carriage 18 is longitudinally moveable to cut the key pattern112 from the master key 110 into the key blade 106 of the key blank 100.

A feature or improvement of the key cutting machine 10 of the presentinvention is that the key cutting machine 10 is operable in three modes:automatic, semi-automatic, and manual. Therefore, with the master key110 and key blank 100 held within the jaws 12 which are mounted on thecarriage 18, the carriage 18 is permitted to move relative to the keycutting machine 10 in three modes.

To operate the key cutting machine 10 in an automatic mode, the masterkey 110 and key blank 100 are placed in the appropriate jaws 12. Thegauge fork 26 is used to verify the proper position and alignment of themaster key 110 and key blank 100 and then rotated to an out of the wayposition as shown in FIG. 7. The carriage 18 is then rotated to acarriage up position (FIG. 5) and the carriage 18 is held against themachine 10 by a roller bearing-plate configuration. As best shown inFIG. 6, a roller bearing 28 is mounted to the carriage 18. With thecarriage 18 in a carriage up position (FIG. 7), the roller bearing 28 isspring biased into engagement and under the guide plate 30. With theroller bearing 28 engaged under the guide plate 30 (as shown in FIGS. 7,9 and 10), the carriage 18 is still moveable longitudinally along thecarriage rod 20 while the carriage 18 is spring biased toward thecutting wheel 24 (as shown in FIG. 9). However, the carriage 18 canstill be partially rotated away from the cutting wheel 24 against thespring bias when required while in the carriage-up engaged position (asshown in FIG. 10).

After the carriage 18 is set in a carriage up position and the rollerbearing 28 engages the guide plate 30, the carriage 18 is moved alongthe carriage rod 20 to a position where the tracer 22 engages the masterkey 110 adjacent the head 102. With the carriage 18 being spring biasedagainst the cutting wheel 24, when the carriage 18 is movedlongitudinally to the left, the tracer 22 engages the pattern 112 in themaster key 110 and the cutting wheel 24 cuts the identical pattern intothe key blank 100. With the carriage 18 in the carriage-up master keyand key blank aligned position, the machine 10 is turned on and theautocycle button is pushed thereby engaging the automatic cycle. Withoutinput from the user, the motor draws the carriage 18 to the left and thekey pattern 112 of the master key 110 is cut into the blade 106 of thekey blank 100. When the carriage 18 gets to a position at the end of thecutting process, the roller bearing 28 will extend beyond and disengagefrom the guide plate 30 and allow the carriage 18 to fall to a carriagedown position as shown in FIG. 6. During such a fall to the carriagedown position, the rotational switch automatically turns the cuttingwheel 24 off. The newly cut key blank is then removed from the jaw andbuffed in the brush 32.

The operation of the key cutting machine 10 in a manual mode isidentical to that of the automatic mode except that the automatic switchis not engaged so as to run the carriage 18 automatically. The masterkey 110 and key blank 100 are placed in the appropriate jaws 12. Thegauge fork 26 is used to verify the proper position and alignment of themaster key 110 and key blank 100 and then rotated to an out of the wayposition. The carriage 18 is then rotated to a carriage up position andthe carriage 18 is held against the machine 10 by the engagement betweenthe roller bearing 28 and guide plate 30. Preferably, the carriage 18 ismoved along the carriage rod 20 to a position where the tracer 22engages the master key 110 adjacent the head 102, although the carriage18 can be moved at any position therealong. With the carriage 18 beingspring biased against the cutting wheel 24, when the carriage 18 ismoved longitudinally to the left by the user through pivoting of thehandle 34, the tracer 22 engages the pattern 112 in the master key 110and the cutting wheel 24 cuts the identical pattern into the key blank100. The user can move the carriage 18 at will longitudinally and themaster key pattern 112 is cut into the key blank 100. When the cuttingprocess is complete, the user simply moves the carriage 18 to a positionat the end of the cutting process so that the roller bearing 28 willextend beyond the guide plate 30 so that the carriage 18 falls to acarriage down position as shown in FIG. 5. During such a fall to thecarriage down position, the rotational switch automatically turns thecutting wheel 24 off. The newly cut key blank is then removed from thejaw 12 and buffed in the brush 32.

The operation of the key cutting machine 10 in a semi-automatic mode isidentical to that of the automatic mode except that at the end of theautomatic cycle when the roller bearing 28 disengages from the guideplate 30, the user can take control of the carriage 18 and move thecarriage 18 to a carriage up position and continue the cutting process.Like all modes, once the roller bearing 28 disengages the guide plate30, the user can move the carriage 18 to the carriage up position andnot engage the roller bearing 28 and guide plate 30 so that the user canmanually move the carriage 18 to continue the cutting process. As thecarriage 18 approaches the carriage up position, the rotational switchengages and the cutting wheel 24 is actuated so that the user canmanually perform the key cutting operation.

To ensure that the key blank 100 and master key 110 are positionedproperly within the key cutting machine 10, the key cutting machine 10includes an additional improvement or feature wherein the jaws 12 areselectable for properly clamping and holding numerous types of keystherein. In particular, the upper and lower jaws 14, 16 are rotatable toprovide separate clamping areas therebetween to accommodate differenttypes of master keys and key blanks for accommodating key width andparticular groove structures. Therefore, depending upon the type ofmaster key and key blank being used, the jaws 12 of the key cuttingmachine 10 must be rotated to accommodate particular key configurations.These such jaw positions can be color coded or identified to assist theoperator in identifying the proper jaws to use with particular masterkey and key blank configurations.

Another improvement or feature of the present invention is a novelassembly to prevent key cutting shavings from interfering with theperformance of the key cutting machine 10. The key cutting machine 10 ofthe present invention includes a housing 40 that mounts over a bottomcover 42. However, the components of the key cutting machine 10 are notmounted on the bottom cover 42 as in most other key cutting machines.With the present invention, all motors, electrical wiring, and switchesare mounted to the underside of the cast housing 40 and above the base42 so that any metal shavings and debris entering the housing 40 willfall past the internal components and collect on the bottom cover 42.Such a configuration will prevent such shavings and debris frominterfering with the operation of the components.

Yet another improvement or feature of the present invention is that theconstruction of major components is modular in form. As shown in theaccompanying drawings, the key cutting machine includes three distinctmodules that are assembled and mounted to the exterior housing. Shouldany of these modules fail, or components of the modules, the entiremachine does not have to be removed or disassembled. Preferably, amodule can be easily replaced by a technician so as to minimize downtime of the machine. Such modularity of components mounted directly onthe housing permits cost effective maintenance and repair of the keycutting machine and ease of access and repair to specific components atthe field level. Modules 1, 2 and 3 are shown in FIG. 2.

Still another improvement or feature of the key cutting machine 10 isthe utilization of a vacuum assembly 60. And while the vacuum assembly60 could be integrally formed with the key cutting machine 10, thepreferred embodiment utilizes a removable vacuum system 60 capable ofbeing connected to the key cutting machine 10. Specifically, theremovable vacuum system 60 has a quick disconnect element permittingselectable connection and disconnection of the vacuum tube. In anembodiment, the quick disconnect element consists of a protrusion 11capable of being received within an aperture 13 of the vacuum port. Theprotrusion 11 and aperture 13 shown in the figures are schematicallyshown only and do not represent any particular precise location or exactshape of the protrusion and aperture.

As shown best in FIG. 1, a vacuum system 60 can be mounted on or nearthe key cutting machine 10 and plugged into a power supply outlet,preferably the power supply outlet 44 as shown in FIG. 5. A housing 62over the cutting wheel 24 prevents access to the cutting wheel 24 toprevent accidental contact therewith. A vacuum port 64 is located withinthe housing 62 so as to provide vacuum communication between theinterior of the housing 62 and the vacuum system 60. The vacuum tube 66is removeably connected to the vacuum port 64 so that when the vacuumtube 66 is connected to the vacuum port 64, the vacuum 60 is capable ofcollecting key shavings from within the housing 62 created during a keycutting operation. When the vacuum tube 66 is disconnected from thevacuum port 64, the vacuum tube 66 can be used as a hand-held vacuumwand to vacuum metal shavings from the key cutting area and surroundingarea for general clean-up. Preferably the vacuum 60 is actuated when thecutting wheel 24 is actuated.

It is also anticipated that the key cutting machine 10 of the presentinvention is also capable of connection to a computer or other mechanism(not shown) so as to interface with a key identification system asdisclosed in the incorporated patent application to make the key cuttingprocess a totally automatic identification, transfer, and cuttingsystem. Such a fully automated system can utilize a robotic arm or othertransfer device that would retrieve a key blank identified by theidentification system and place that key blank into the locking jaws 12so that a user would not have to operate the key cutting machine 10 ortransfer the key blank to the key cutting machine 10.

A further improvement or feature of the key cutting machine 10 is acarriage and rotating arm having an improved lever latch and carriagelocking mechanism as shown in FIGS. 5, 7 and 11. The locking mechanismlocks the carriage 18 and stops the cutter after the key is cut. Theuser is then required to pull the trigger 70 to release the latchingmechanism 72 on the carriage 18 to permit movement of the carriage 18and activation of the cutting wheel 24 so as not to accidentallyactivate the cutting wheel 24.

1. A key cutting machine comprising: a housing; a carriage supported onsaid housing; a key clamp connected to said carriage; a key cuttingelement located at least partially within said housing; and a motorconnected to and capable of driving said carriage.
 2. The key cuttingmachine of claim 1 further comprising a vacuum port, wherein said vacuumport includes a quick-disconnect element permitting selectableconnection and disconnection of said vacuum tube.
 3. The key cuttingmachine of claim 2 wherein said quick-disconnect element comprises atleast one aperture for receiving at least one connection elementassociated with said vacuum tube.
 4. The key cutting machine of claim 2wherein said quick-disconnect element comprises at least one protrusioncapable of being received within at least one aperture associated withsaid vacuum tube.
 5. The key cutting machine of claim 1 furthercomprising at least one power supply outlet integral therewith forelectrically connecting an external electrical device thereto.
 6. Thekey cutting machine of claim 5 wherein said power supply outlet isactivated only when said key cutting element is activated.
 7. The keycutting machine of claim 6 wherein said external electrical device is avacuum device having a vacuum tube capable of removable connection tosaid vacuum port.
 8. A key cutting machine comprising: a housing havinga vacuum port; a key cutting element located at least partially withinsaid housing; a vacuum device; a tube connected to said vacuum deviceand removeably connected to said vacuum port, so that when said tube isconnected to said vacuum port, said vacuum device is capable ofcollecting key shavings created during the key cutting operation and,when said tube is disconnected from said vacuum port, said tube can beused to collect key shavings in an area generally surrounding said keycutting machine.
 9. The key cutting machine of claim 8 wherein saidvacuum port includes a quick-disconnect element permitting reliableconnection and disconnection of said vacuum tube.
 10. The key cuttingmachine of claim 9 wherein said quick-disconnect element comprises atleast one aperture for receiving at least one connection elementassociated with said vacuum tube.
 11. A key cutting machine comprising:a housing; a carriage supported on said housing; a key clamp connectedto said carriage; a key cutting element located at least partiallywithin said housing; and a motor connected to and capable of drivingsaid carriage.
 12. The key cutting machine of claim 10 furthercomprising a vacuum port, wherein said vacuum port includes aquick-disconnect element permitting selectable connection anddisconnection of said vacuum tube.
 13. The key cutting machine of claim12 wherein said quick-disconnect element comprises at least one aperturefor receiving at least one connection element associated with saidvacuum tube.
 14. The key cutting machine of claim 12 wherein saidquick-disconnect element comprises at least one protrusion capable ofbeing received within at least one aperture associated with said vacuumtube.
 15. The key cutting machine of claim 11 further comprising atleast one power supply outlet integral therewith for electricallyconnecting an external electrical device thereto.
 16. The key cuttingmachine of claim 15 wherein said power supply outlet is activated onlywhen said key cutting element is activated.
 17. The key cutting machineof claim 16 wherein said external electrical device is a vacuum devicehaving a vacuum tube capable of removable connection to said vacuumport.